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Home >> Ford >> 2009 >> Flex Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 870 (Front Drive Axle/Differential - DANA 35) >> Diagnostic Tests >> Front Drive Axle >> Diagnostic Routines

Diagnostic Routines

WARNING: This page is about a different car, the 2007 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
DIAGNOSTIC ROUTINE - FLUID LOSS

Possible Component Reference/Action
Vent CLEAN the axle vent and vent hose.
Overfilled axle CHECK the lubricant level for specific amount.
Fill plug CLEAN the area around the plug. REMOVE the plug. APPLY pipe sealant and INSTALL the plug.
Halfshaft oil seal INSTALL a new halfshaft oil seal.
Pinion seal INSTALL a new pinion seal.
Differential housing cover RESEAL the differential housing cover.
DIAGNOSTIC ROUTINE - NOISE LOUDER ON TURNS (SWEEPING)

Possible Component Reference/Action
Wheel end bearing CHECK the wheel end bearing for wear or damage. INSTALL a new bearing.
DIAGNOSTIC ROUTINE - NOISE (GROWL) IN TIGHT TURN, CONVENTIONAL DIFFERENTIAL

Possible Component Reference/Action
Differential side gears and differential pinion gears DISASSEMBLE the differential carrier. INSPECT the differential case assembly. INSTALL new side gears and differential pinion gears or case assembly.
DIAGNOSTIC ROUTINE - NOISE (WHINE) IN ALL OR MORE THAN ONE DRIVE MODES

Possible Component Reference/Action
Axle ring and pinion REMOVE and INSTALL a new gear set and bearings.
DIAGNOSTIC ROUTINE - NOISE (TICK/CLICK) IN ALL OR MORE THAN ONE DRIVE MODES

Possible Component Reference/Action
Axle ring and pinion REMOVE and INSTALL a new ring gear, pinion and bearings.
DIAGNOSTIC ROUTINE - NOISE (HOWL/MOAN) IN ALL OR MORE THAN ONE DRIVE MODES

Possible Component Reference/Action
Axle bearings INSPECT differential and pinion bearings. INSTALL new bearings.
DIAGNOSTIC ROUTINE - NOISE (CLUNK) ON CHANGES IN SPEED OR DIRECTION OF POWER

Possible Component Reference/Action
Axle and pinion system MEASURE total backlash. If end play and total backlash are within specification, INSTALL a new differential case assembly.
Differential pinion shaft INSTALL a new differential pinion shaft and pin.
Pinion bearings INSTALL new pinion and differential bearings and bearing cups.
DIAGNOSTIC ROUTINE - FRONT AXLE WILL NOT ENGAGE/DISENGAGE

Possible Component Reference/Action
Mode switch
Wiring
Shift motor
REFER to FOUR WHEEL DRIVE (4WD) SYSTEMS .
DIAGNOSTIC ROUTINE - VIBRATION

Possible Component Reference/Action
For driveline vibration, REFER to NOISE, VIBRATION AND HARSHNESS .